U.S. patent application number 15/550946 was filed with the patent office on 2018-01-25 for tank and heat exchanger.
The applicant listed for this patent is DENSO CORPORATION. Invention is credited to Ken MUTOU, Takeshi OKINOTANI, Syunsuke TSUBOTA.
Application Number | 20180023903 15/550946 |
Document ID | / |
Family ID | 57070996 |
Filed Date | 2018-01-25 |
United States Patent
Application |
20180023903 |
Kind Code |
A1 |
MUTOU; Ken ; et al. |
January 25, 2018 |
TANK AND HEAT EXCHANGER
Abstract
A tank has a tank body defining a passage therein, a plate to
which tubes are attached, and an intermediate plate. The tank body
has a space defining part and a tank junction part attached to the
intermediate plate. A longitudinal direction and a stacking
direction of the tubes are perpendicular to a width direction. The
space defining part has two end parts facing each other in the
width direction and connecting to two of the tank junction part
respectively. The tank body has a junction end surface that has an
arc shape protruding toward the passage. The intermediate plate has
a part corresponding to the junction end surface and being provided
with a receiving surface that has an arc shape fitting the arc
shape of the junction end surface. The receiving surface is
attached to the junction end surface.
Inventors: |
MUTOU; Ken; (Kariya-city,
JP) ; OKINOTANI; Takeshi; (Kariya-city, JP) ;
TSUBOTA; Syunsuke; (Kariya-city, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DENSO CORPORATION |
Kariya-city, Aichi-pref. |
|
JP |
|
|
Family ID: |
57070996 |
Appl. No.: |
15/550946 |
Filed: |
March 18, 2016 |
PCT Filed: |
March 18, 2016 |
PCT NO: |
PCT/JP2016/001579 |
371 Date: |
August 14, 2017 |
Current U.S.
Class: |
165/175 |
Current CPC
Class: |
F28F 9/0229 20130101;
F28D 1/05383 20130101; F28F 2225/08 20130101; F28F 1/022 20130101;
F25B 2309/061 20130101; F25B 39/00 20130101; F28F 9/0278 20130101;
F25B 39/04 20130101; F25B 9/008 20130101; F28F 9/0224 20130101 |
International
Class: |
F28F 9/02 20060101
F28F009/02; F28D 1/053 20060101 F28D001/053 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 20, 2015 |
JP |
2015-057470 |
Mar 15, 2016 |
JP |
2016-051175 |
Claims
1. (canceled)
2. A tank having a passage in which a fluid flows, the passage
communicating with insides of a plurality of tubes in which the
fluid flows, the plurality of tubes being stacked in a stacking
direction, the tank comprising: a tank body that defines the
passage therein; a plate to which the plurality of tubes are
attached; and an intermediate plate that has a plate shape and is
arranged between the tank body and the plate, wherein each of the
plurality of tubes has a longitudinal end in a longitudinal
direction of the plurality of tubes, the longitudinal end
connecting to the passage through a communicating portion that is
located between the passage and the longitudinal end, the passage
has a round part having a round shape in cross section when viewed
in the stacking direction, the round part including at least a top
located away from the plurality of tubes, the tank body has a space
defining part that defines the passage and a tank junction part
that has a plate shape and is attached to the intermediate plate,
the longitudinal direction and the stacking direction of the
plurality of tubes are perpendicular to a width direction, the
space defining part has two end parts facing each other in the
width direction, the two end parts connecting to two of the tank
junction part respectively, the tank body has a junction end
surface that has an arc shape protruding toward the passage when
viewed in the stacking direction, the junction end surface being
located adjacent to the passage and included in a junction area in
which the space defining part connects to the tank junction part,
and the intermediate plate has a part corresponding to the junction
end surface, the part being provided with a receiving surface that
has an arc shape fitting the arc shape of the junction end surface,
the receiving surface being attached to the junction end
surface.
3. The tank according to claim 2, wherein the part of the
intermediate plate corresponding to the junction end surface is
provided with a protruding portion protruding toward the tank body,
and the protruding portion has the receiving surface.
4. The tank according to claim 2, wherein the intermediate plate
has an intermediate junction part that has a plate shape and is
attached to the tank junction part of the tank body and a
protruding part that has a plate shape and located closer to the
top as compared to the intermediate junction part, the protruding
part is provided with the communicating portion, and the
intermediate junction part connects to the protruding part in a
junction area having the receiving surface.
5. The tank according to claim 2, wherein the tank is used in a
heat exchanger that performs a heat exchange between the fluid
flowing in the plurality of tubes and another fluid flowing outside
the plurality of tubes.
6. The tank according to claim 2, further comprising a swaging part
that fixes the tank body, the plate, and the intermediate plate
together temporarily, wherein the tank body, the plate, and the
intermediate plate are joined together by brazing.
7.-9. (canceled)
10. A heat exchanger comprising: a plurality of tubes being stacked
in a stacking direction and defining conduits in which a fluid
flows respectively; and a pair of tanks that extends in the
stacking direction, the plurality of tubes connecting the pair of
tanks to each other, wherein each of the pair of tanks has a plate
to which one longitudinal ends of the plurality of tubes are
attached, a tank body that is attached to the plate and has a
passage extending in the stacking direction, and an intermediate
plate that has a plate shape and is arranged between the tank body
and the plate, the tank body has a space defining part that defines
the passage such that at least a part of the passage has a round
shape in cross section when viewed in the stacking direction, and a
tank junction part being attached to the intermediate plate, the
tank junction part extending in a width direction perpendicular to
both the stacking direction and a longitudinal direction of the
plurality of tubes when viewed in the stacking direction, the space
defining part having two end parts facing each other in the width
direction, the two end parts connecting to two of the tank junction
parts respectively, the tank body has a junction end surface that
has an arc shape protruding toward the passage when viewed in the
stacking direction, the junction end surface being located adjacent
to the passage and included in a junction area in which the space
defining part connects to the tank junction part, and the
intermediate plate has a part corresponding to the junction end
surface, the part being provided with a receiving surface that has
an arc shape fitting the arc shape of the junction end surface, the
receiving surface being attached to the junction end surface.
11. The heat exchanger according to claim 10, wherein the
intermediate plate has an intermediate junction part that has a
plate shape and is attached to the tank junction part of the tank
body and a protruding part that has a plate shape and protrudes
toward the passage to be located closer to the passage as compared
to the intermediate junction part, the intermediate junction part
connects to the protruding part in a junction area having the
receiving surface, and the protruding part has flat surfaces that
face each other in the width direction and that are attached to an
inner wall surface of the space defining part.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on Japanese Patent Application No.
2015-057470 filed on Mar. 20, 2015 and Japanese Patent Application
No. 2016-051175 filed on Mar. 15, 2016, the disclosures of which
are incorporated herein by reference.
Technical Field
[0002] The present disclosure relates to a tank in which a fluid
flows and a heat exchanger having the tank.
Background Art
[0003] Conventionally, a refrigeration cycle using carbon dioxide
as refrigerant is known. The refrigeration cycle has a refrigerant
radiator (i.e., a heat exchanger for radiating heat). Since a
pressure in the refrigeration cycle becomes high, components
configuring the refrigerant radiator are required to have pressure
resistance. Especially, a tank is required to have higher pressure
resistance since the tank has the largest passage sectional area in
the refrigerant radiator, as described in Patent Literature 1.
[0004] Then, a heat exchanger having a tank that is configured by
three members of a tank body, a plate, and an intermediate plate is
disclosed (e.g., refer to Patent Literature 2). The refrigerant
flows in the tank body. The plate is connected with tubes. The
intermediate plate has a plate shape and is arranged between the
tank body and the plate. According to the above-described
configuration having the three members, a junction area between
each of the three members can be secured easily, and thereby the
tank can have greater pressure resistance as a whole.
PRIOR ART LITERATURES
Patent Literature
[0005] Patent Literature 1: JP 2003-314987 A
[0006] Patent Literature 2: JP 2007-278556 A
SUMMARY OF INVENTION
[0007] According to studies conducted by the inventors of the
present disclosure, the tank body of the tank disclosed in Patent
Literature 1 may be made by pressing. In this case, a shear drop
having an arc shape in cross section is formed in a corner of the
junction area between the tank body and the intermediate plate. The
sear drop of the tank body is stressed intensively when an inner
pressure of the tank increases, and thereby the pressure resistance
of the tank may deteriorate.
[0008] Accordingly, it is required to suppress the sear drop to
reduce the stress applied to the sear drop intensively. For
example, the shape of the corner of the junction area in cross
section is necessary to be a square shape substantially. However,
the pressing is required to be performed repeatedly so as to
prevent the sear drop from being formed in the pressing. As a
result, a quantity of machining processes increases, and thereby
productivity may deteriorate.
[0009] The present disclosure addresses the above-described issues,
and it is an objective of the present disclosure to provide a tank
that can have pressure resistance certainly while improving
productivity.
[0010] It is another objective to provide a heat exchanger having
the tank that can have pressure resistance certainly while
improving productivity.
[0011] According to a first aspect of the present disclosure, a
tank has a passage in which a fluid flows. The passage and insides
of tubes in which the fluid flows communicate with each other. The
tubes are stacked in a stacking direction.
[0012] The tank has a tank body, a plate, and an intermediate
plate. The tank body defines the passage therein. The tubes are
attached to the plate. The intermediate plate has a plate shape and
is arranged between the tank body and the plate. Each of the tubes
has a longitudinal end in a longitudinal direction of the tubes.
The longitudinal end connects to the passage through a
communicating portion that is located between the passage and the
longitudinal end. The passage has a round part having a round shape
in cross section when viewed in the stacking direction. The round
part includes at least a top located away from the tubes. The tank
body has a space defining part and a tank junction part. The space
defining part defines the passage. The tank junction part has a
plate shape and is attached to the intermediate plate.
[0013] The longitudinal direction and the stacking direction of the
tubes are perpendicular to a width direction. The space defining
part has two end parts facing each other in the width direction.
The two end parts connect to two of the tank junction part
respectively. The space defining part has an inner wall surface on
a side adjacent to the passage. The inner wall surface has a top
located furthermost from the tubes in the inner wall surface. The
tank body has a junction area in which the space defining part
connects to the tank junction part. The junction area has a
junction edge located closest to the tubes in the junction area
when viewed in the stacking direction. The tank body has a shape
satisfying expressions given by D1>D2 and D2.times.L.gtoreq.A1.
D1 represents a diameter of an inscribed circle including the top
of the space defining part of the tank body when viewed in the
stacking direction. D2 represents a distance between the two
junction edges facing each other in the width direction in the tank
body when viewed in the stacking direction. L represents a length
of the passage in the stacking direction. A1 represents a total
area of passage sectional areas of the tubes.
[0014] As described above, the tank body has a shape satisfying the
expressions given by D1>D2 and D2.times.L.gtoreq.A1.
Accordingly, it can suppress that stress is intensively applied to
the junction part in which the space defining part connects to the
tank junction part, i.e., to a corner of a junction part in which
the tank body is attached to the intermediate part. In addition, a
pressing process is not necessary to provide the junction area in
which the space defining part connects to the tank junction part to
have a square shape, thereby a quantity of machining processes can
be reduced. Therefore, the tank can have high pressure resistance
certainly while productivity is improved.
[0015] According to a second aspect of the present disclosure, a
tank has a passage in which a fluid flows. The passage and insides
of tubes in which the fluid flows communicate with each other. The
tubes are stacked in a stacking direction.
[0016] The tank has a tank body, a plate, and an intermediate
plate. The tank body defines the passage therein. The tubes are
attached to the plate. The intermediate plate has a plate shape and
is arranged between the tank body and the plate. Each of the tubes
has a longitudinal end in a longitudinal direction of the tubes.
The longitudinal end connects to the passage through a
communicating portion that is located between the passage and the
longitudinal end. The passage has a round part having a round shape
in cross section when viewed in the stacking direction. The round
part includes at least a top located away from the tubes. The tank
body has a space defining part and a tank junction part. The space
defining part defines the passage. The tank junction part has a
plate shape and is attached to the intermediate plate.
[0017] The longitudinal direction and the stacking direction of the
tubes are perpendicular to a width direction. The space defining
part has two end parts facing each other in the width direction.
The two end parts connect to two of the tank junction part
respectively. The tank body has a junction end surface that has an
arc shape protruding toward the passage when viewed in the stacking
direction. The junction end surface is located adjacent to the
passage and included in a junction area in which the space defining
part connects to the tank junction part. The intermediate plate has
a part corresponding to the junction end surface. The part is
provided with a receiving surface that has an arc shape fitting the
arc shape of the junction end surface. The receiving surface is
attached to the junction end surface.
[0018] According to the second aspect, an inner wall surface of the
tank body smoothly joins an inner side of the intermediate plate in
a manner that the intermediate plate has a receiving surface that
has the arc shape fitting the arc shape of the junction end
surface. Accordingly, it can suppress that stress is intensively
applied to the junction part in which the space defining part
connects to the tank junction part, i.e., to a corner of a junction
part in which the tank body is attached to the intermediate part.
In addition, a pressing process is not necessary to provide the
junction area in which the space defining part connects to the tank
junction part to have a square shape, thereby a quantity of
machining processes can be reduced. Therefore, the tank can have
high pressure resistance certainly while productivity is
improved.
[0019] According to a third aspect of the present disclosure, a
heat exchanger has tubes, a pair of tanks, an inlet, and an outlet.
The tubes are stacked in a stacking direction and define conduits
in which a fluid flows respectively. Each of the tubes therein
defines a passage in which a fluid flows. The pair of tanks extends
in the stacking direction. The tubes connect the pair of tanks to
each other. The inlet guides the fluid to flow into at least one
tank of the pair of tanks. The outlet guides the fluid to flow out
of the one tank.
[0020] Each of the pair of tanks has a plate, a tank body, and an
intermediate plate. One longitudinal ends of the tubes are attached
to the plate. The tank body is attached to the plate and has a
passage extending in the stacking direction. The intermediate plate
has a plate shape and is arranged between the tank body and the
plate.
[0021] The tank body has a space defining part, a tank junction
part, and an opening. The space defining part defines the passage
such that at least a part of the passage has a round shape in cross
section when viewed in the stacking direction. The tank junction
part is attached to the intermediate plate. The tank junction part
extends in a width direction perpendicular to both the stacking
direction and a longitudinal direction of the tubes when viewed in
the stacking direction. The space defining part has two end parts
facing each other in the width direction. The two end parts connect
to two of the tank junction parts respectively. The opening is
defined between the two of the tank junction parts in the width
direction. Insides of the tubes and the passage communicate with
each other through the opening. At least the one tank has a tank
inlet part that distributes the fluid, flowing from the inlet, to
the plurality of tubes.
[0022] The tank body has a shape satisfying expressions given by:
D1>D2 and D2.times.L.gtoreq.A.times.n. D1 represents a diameter
of a largest inscribed circle in cross sections of the passage when
viewed in the stacking direction. D2 represents a width of the
opening in the width direction. L represents a length of the tank
inlet part in the passage in the stacking direction. A represents a
passage sectional area of each of the tubes connecting to the tank
inlet part. The n represents a quantity of the tubes connecting to
the tank inlet part.
[0023] According to the third aspect, it can be provide the heat
exchanger that has the tank having high pressure resistance
certainly while productivity is improved.
[0024] According to a fourth aspect of the present disclosure, a
heat exchanger has tubes and a pair of tanks. The tubes are stacked
in a stacking direction and define conduits in which a fluid flows
respectively. Each of the pair of tanks extends in the stacking
direction. The tubes connect the pair of tanks to each other.
[0025] Each of the pair of tanks has a plate, a tank body, and an
intermediate plate. One longitudinal ends of the tubes are attached
to the plate. The tank body is attached to the plate and has a
passage extending in the stacking direction. The intermediate plate
has a plate shape and is arranged between the tank body and the
plate.
[0026] The tank body has a space defining part, a tank junction
part, and an opening. The space defining part defines the passage
such that at least a part of the passage has a round shape in cross
section when viewed in the stacking direction. The tank junction
part is attached to the intermediate plate. The tank junction part
extends in a width direction perpendicular to both the stacking
direction and a longitudinal direction of the tubes when viewed in
the stacking direction. The space defining part has two end parts
facing each other in the width direction. The two end parts
connecting to two of the tank junction parts respectively. The
opening is defined between the two of the tank junction parts in
the width direction. Insides of the tubes and the passage
communicate with each other through the opening. The intermediate
plate has a plate hole through which the tubes and the passage
communicate with each other.
[0027] The tank body has a shape satisfying expressions given by:
D1>D2 and D2.times.t1.gtoreq.A.times.n. D1 represents a diameter
of a largest inscribed circle in cross sections of the passage when
viewed in the stacking direction. D2 represents a width of the
opening in the width direction. t1 represents a thickness dimension
of the plate hole in the stacking direction. A represents a passage
sectional area of each of the tubes connecting to the tank inlet
part.
[0028] Therefore, a heat exchanger that has the tank having high
pressure resistance certainly while productivity is improved can be
provided.
[0029] According to a fifth aspect of the present disclosure, a
heat exchanger has tubes and a pair of tanks. The tubes are stacked
in a stacking direction and define conduits in which a fluid flows
respectively. The pair of tanks extends in the stacking direction.
The tubes connect the pair of tanks to each other.
[0030] Each of the pair of tanks has a plate, a tank body, and an
intermediate plate. One longitudinal ends of the tubes are attached
to the plate. The tank body is attached to the plate and has a
passage extending in the stacking direction. The intermediate plate
has a plate shape and is arranged between the tank body and the
plate.
[0031] The tank body has a space defining part and a tank junction
part. The space defining part defines the passage such that at
least a part of the passage has a round shape in cross section when
viewed in the stacking direction. The tank junction part is
attached to the intermediate plate. The tank junction part extends
in a width direction perpendicular to both the stacking direction
and a longitudinal direction of the tubes when viewed in the
stacking direction. The space defining part has two end parts
facing each other in the width direction. The two end parts connect
to two of the tank junction parts respectively.
[0032] The tank body has a junction end surface that has an arc
shape protruding toward the passage when viewed in the stacking
direction. The junction end surface is located adjacent to the
passage and included in a junction area in which the space defining
part connects to the tank junction part. The intermediate plate has
a part corresponding to the junction end surface. The part is
provided with a receiving surface that has an arc shape fitting the
arc shape of the junction end surface. The receiving surface is
attached to the junction end surface.
[0033] According to the fifth aspect, a heat exchanger that has the
tank having high pressure resistance certainly while productivity
is improved can be provided.
BRIEF DESCRIPTION OF DRAWINGS
[0034] The above and other objects, features and advantages of the
present disclosure will become more apparent from the following
detailed description made with reference to the accompanying
drawings.
[0035] FIG. 1 is a front view illustrating a refrigerant radiator
according to a first embodiment.
[0036] FIG. 2 is a cross-sectional view illustrating tubes taken
along a line perpendicular to a longitudinal direction of the tubes
according to the first embodiment.
[0037] FIG. 3 is a cross-sectional view taken along a line III-III
shown in FIG. 1.
[0038] FIG. 4 is a cross-sectional view taken along a line IV-IV
shown in FIG. 3.
[0039] FIG. 5 is an exploded perspective view illustrating one of
the tubes and a header tank according to the first embodiment.
[0040] FIG. 6 is a cross-sectional view illustrating a tank body
when viewed in a tube stacking direction, according to the first
embodiment.
[0041] FIG. 7 is an exploded cross-sectional view illustrating a
tank body and an intermediate plate when viewed in the tube
stacking direction, according to a second embodiment.
[0042] FIG. 8 is an exploded cross-sectional view illustrating a
tank body and an intermediate plate when viewed in the tube
stacking direction, according to a third embodiment.
[0043] FIG. 9 is a cross-sectional view illustrating a header tank
according to a fourth embodiment.
[0044] FIG. 10 is an exploded cross-sectional view illustrating a
tank body and an intermediate plate when viewed in the tube
stacking direction, according to a fifth embodiment.
[0045] FIG. 11 is a cross-sectional view illustrating one of tubes
and a header tank when viewed in the tube stacking direction,
according to a modification.
DESCRIPTION OF EMBODIMENTS
[0046] Embodiments of the present disclosure will be described
hereafter referring to drawings. In the embodiments, a part that
corresponds to or equivalents to a matter described in a preceding
embodiment may be assigned with the same reference number, and a
redundant description may be omitted. When only a part of a
configuration is described in an embodiment, another preceding
embodiment may be applied to the other parts of the configuration.
The parts may be combined even if it is not explicitly described
that the parts can be combined. The embodiments may be partially
combined even if it is not explicitly described that the
embodiments can be combined, provided there is no harm in the
combination.
First Embodiment
[0047] A first embodiment will be described hereafter referring to
FIG. 1 through FIG. 6. According to the present embodiment, a tank
of the present disclosure is applied to a header tank of a
refrigerant radiator that is disposed in a supercritical
refrigeration cycle using carbon dioxide (CO.sub.2) as refrigerant.
The supercritical refrigeration cycle is a refrigeration cycle that
may use, other than carbon dioxide, ethylene, ethane, nitric oxide
etc. as the refrigerant. A pressure on a high-pressure side in the
supercritical refrigeration cycle exceeds a critical pressure of
the refrigerant.
[0048] As shown in FIG. 1, a refrigerant radiator 100 is a heat
exchanger that performs a heat exchange between the refrigerant
flowing in tubes 110 and air flowing outside the tubes 110.
According to the present embodiment, the refrigerant corresponds to
a fluid, and the air corresponds to another fluid.
[0049] The refrigerant radiator 100 has a core 101 and a pair of
header tanks 140. Each member configuring the core 101 and the pair
of header tanks 140 is made of aluminum or an aluminum alloy. The
members configuring the core 101 and the pair of header tanks 140
are assembled by a method such as fitting and a fixing using a jig
and are joined together by brazing. A brazing material is applied
to surfaces of the members as required in advance.
[0050] The core 101 has the tubes 110 and fins 120. The tubes have
a flat shape in cross section and define conduits in which
refrigerant flows respectively. The fins 120 have a corrugated
shape. The tubes 110 and the fins 120 are stacked alternately with
each other.
[0051] A longitudinal direction of the tubes 110 will be referred
to as a tube longitudinal direction hereafter. A stacking direction
in which the tubes 110 and the fins 120 are stacked will be
referred to as a tube stacking direction. A direction perpendicular
to both the tube longitudinal direction and the tube stacking
direction will be referred to as a width direction.
[0052] Each of the tubes 110 has conduits 110a therein. The
conduits 110a are arranged in a longitudinal direction of the flat
shape of the tubes 110. Specifically, as shown in FIG. 2, a
quantity of the conduits 110a provided in each of the tubes 110 is
nine, and the conduits 110a has a circular shape in cross section.
Accordingly, a passage sectional area A of each of the tubes 110 is
equal to a total area of passage sectional areas of the conduits
110a. That is, when each of the tubes 110 has a single conduit, the
passage sectional area A of each of the tubes 110 is equal to a
passage sectional area of the single conduit. The tubes 110 are
formed by extrusion molding.
[0053] As shown in FIG. 1, the core 101 has two edges facing each
other in the tube stacking direction, and a side plate 130 is
attached to each of the two edges. The side plate 130 reinforces
the core 101. The side plate 130 extends parallel to the tube
longitudinal direction and has two end parts in the tube
longitudinal direction. The two end parts are attached to the
header tanks 140 respectively.
[0054] The header tanks 140 are located on both sides of the tubes
110 in the tube longitudinal direction respectively, and extend in
a direction (i.e., the tube stacking direction) perpendicular to
the tube longitudinal direction. The header tanks 140 communicate
with the tubes 110. According to the present embodiment, the header
tanks 140 are located on horizontal sides of the tubes 110 facing
each other in horizontal direction, and extend in vertical
direction to communicate with the tubes 110.
[0055] More specifically, each of the header tanks 140 has a
passage 151 therein. The header tanks 140 and the tubes 110 are
coupled with each other by brazing such that an inside of the
passage 151 and insides of the tubes 110 communicate with each
other. Each of the header tanks 140 has longitudinal ends (i.e.,
ends in the tube stacking direction), and an end cap 180 is
attached to each of the longitudinal ends by brazing. The end cap
180 seals an opening of the passage 151 provided in the header
tanks 140.
[0056] One header tank 140 of the pair of header tanks 140 has a
separator 141. The separator 141 is located in the one header tank
140 and partitions the passage 151. The separator 141 is attached
to the one header tank 140 by brazing. The one header tank 140 is
located on a left side on a condition of being illustrated in FIG.
1. The one header tank 140 has an inlet joint 191. The inlet joint
191 is located above the separator 141 and attached to the one
header tank 140 by brazing. The inlet joint 191 provides an inlet,
and the refrigerant flows into the passage 151 from the inlet. The
one header tank 140 further has an outlet joint 192. The outlet
joint 192 is located below the separator 141 and attached to the
one header tank 140 by brazing. The outlet joint 192 provides an
outlet, and the refrigerant flows out of the passage 151 from the
outlet.
[0057] A configuration of the header tanks 140 of the present
embodiment will be described in detail hereafter. As shown in FIG.
3, FIG. 4, and FIG. 5, each of the header tanks 140 has a tank body
150, a plate 160, and an intermediate plate 170. The tank body
defines the passage 151, in which the refrigerant flows, therein.
The tubes 110 are attached to the plate 160. The intermediate plate
170 has a plate shape and is arranged between the tank body 150 and
the plate 160.
[0058] The tank body 150 has a space defining part 152 and a tank
junction part 153. The space defining part 152 defines the passage
151. The tank junction part 153 is attached to the plate 160 and
the intermediate plate 170.
[0059] As shown in FIG. 3 and FIG. 4, the space defining part 152
has a substantially arc shape in cross section when viewed in the
tube stacking direction. That is, the space defining part 152 is
provided such that at least a part of an inner wall surface of the
space defining part 152 has substantially arc shape. The inner wall
surface is, i.e., a surface adjacent to the passage 151.
Accordingly, the passage 151 has a round part that has a round
shape and includes a top 154 located furthermost from the tubes
110, in cross section of the passage 151 viewed in the tube
stacking direction.
[0060] The space defining part 152 has an opening 155 on a side
adjacent to the tubes 110 (i.e., a side adjacent to the
intermediate plate 170). One longitudinal ends of the tubes 110 in
the longitudinal direction and the passage 151 communicate with
each other through the opening 155. The one longitudinal ends of
the tubes 110 will be referred to as tube ends 111 hereafter.
[0061] The space defining part 152 has two ends facing each other
in the width direction. The tank junction part 153 has a plate
shape and connects the two ends to each other. In other words, the
space defining part 152 has one end and an other end facing each
other in the width direction, and the tank junction part 153
connects to each of the one end and the other end. As a result, the
opening 155 is located between two of the tank junction part 153
when viewed in the tube stacking direction. The space defining part
152 and the tank junction part 153 are provided integrally with
each other.
[0062] The tank body 150 having the above-described space defining
part 152 and the tank junction part 153 is provided by pressing a
flat plate that is cladded with (i.e., coated with) a brazing
material in advance. The brazing material covers a surface of the
flat plate on the side adjacent to the tubes 110. The brazing
material may cover the one surface and another surface of the flat
plate facing the one surface.
[0063] The plate 160 has a substantially U-shape. Specifically, the
plate 160 has two bent portions extending in one direction when
viewed in the tube stacking direction. More specifically, the plate
160 has a flat part 161 and ribs 162. The flat part 161 has a
rectangular flat shape and has two ends facing each other in the
width direction. The ribs 162 connect to the two ends of the flat
part 161 respectively. The flat part 161 and the ribs 162 are
provided integrally with each other.
[0064] The flat part 161 of the plate 160 is provided with a tube
insert hole 163 to which the tube end 111 is inserted. The plate
160 is provided by pressing a flat plate that is cladded with a
brazing material on both of a top side and a bottom side facing
each other.
[0065] The intermediate plate 170 has a rectangular flat shape. The
intermediate plate 170 has a part corresponding to the tube end
111, and the part is provided with a plate hole 171 passing through
the intermediate plate 170 in a thickness direction of the
intermediate plate 170. As shown in FIG. 5, the plate hole 171 has
a longitudinal end part provided with a stepped portion 172. The
stepped portion 172 is provided as a position setting portion that
sets a position of the tube end 111 in the thickness direction.
[0066] A thickness dimension t1 of the plate hole 171 in the
thickness direction is larger than a thickness dimension t2 of the
each tube 110 in the thickness direction. The dimension t1 is,
i.e., a length of the plate hole 171 in the tube stacking
direction. The thickness dimension t2 is, i.e., a dimension of each
tube 110 in a transverse direction in the flat cross-sectional
shape or a length of each tube 110 in the tube stacking direction.
According to the present embodiment, the thickness dimension t1 is
about twice as large as of the thickness dimension t2. The
intermediate plate 170 is different from the tank body 150 and the
plate 160 in a point that the intermediate plate 170 is configured
by a bare member of which surface is not cladded.
[0067] The tank body 150, the intermediate plate 170, plate 160,
and the tubes 110 having the above-described configurations are
assembled as shown in FIG. 3 and FIG. 4. A location of an edge 112
of the tube end 111 is set to be located in an area outside the
passage 151 by the stepped portion 172 of the plate hole 171
provided in the intermediate plate 170. The tube end 111 is located
inside the plate hole 171.
[0068] The opening 155 of the tank body 150 and the plate hole 171
of the intermediate hole 170 provide a communicating portion
through which the tube end 111 connects to the passage 151. The
members 150, 170, 160, 110 are brazed integrally by a brazing
material applied to the tank body 150 and the plate 160.
[0069] The tank body 150 of the present embodiment will be
described in detail hereafter referring to FIG. 6. The tank body
150 has a surface adjacent to the passage 151 defining a junction
area in which the space defining part 152 connects to the tank
junction part 153. The surface will be referred to as a junction
end surface 156.
[0070] The junction end surface 156 inclines from an inside to an
outside in the width direction (i.e., from an inside to an outside
of a paper showing FIG. 6) as being distanced away from the tube
110 in the tube longitudinal direction (from a lower side to an
upper side of the paper showing FIG. 6). According to the present
embodiment, the junction end surface 156 has an arc shape that is
recessed toward the outside in the width direction. More
specifically, the junction end surface 156 is located on a circle
defined by the inner wall surface of the space defining part 152
having the substantially arc shape. Therefore, the junction end
surface 156 and the inner wall surface (i.e., an arc surface)
connect to each other smoothly.
[0071] The inner wall surface of the space defining part 152
included in the tank body 150 has a top 157 located furthermost
from the tube end 111. The tank body 150 has the junction area in
which the space defining part 152 connects to the tank junction
part 153. The junction area has a junction edge 158 located closest
to the tube end 111 when viewed in the tube stacking direction.
Since the junction end surface 156 has the arc shape, the junction
end surface 156 has one edge and an other edge facing each other in
the width direction. According to the present embodiment, each of
the one edge and the other edge has the junction edge 158.
[0072] Here, D1 represents a diameter of an inscribed circle (shown
by a dashed line in FIG. 6) including the top 157 of the space
defining part 152 when viewed in the stacking direction. In other
words, D1 represents a diameter of an inscribed circle having the
largest diameter in the passage 151 when viewed in the tube
stacking direction.
[0073] D2 represents a distance between the two junction edges 158
of the tank body 150 facing each other in the width direction when
viewed in the stacking direction. That is, D2 represents a distance
between the junction edge 158 provided in the one edge and the
junction edge 158 provided in the other edge in the width
direction. In other words, D2 represents a width of the opening
155.
[0074] L represents a length of the passage 151 in the stacking
direction. Specifically, the header tank 140 has a tank inlet part
140a that distributes the fluid, flowing from the inlet joint 191,
to the tubes 110. According to the present embodiment, the tank
inlet part 140a is a part of the one header tank 140 and is located
above the separator 141. As shown in FIG. 1, the length L is, i.e.,
a length of the tank inlet part 140a in the passage 151 in the tube
stacking direction.
[0075] A1 represents a total area of passage sectional areas of the
tubes 110. Specifically, a passage sectional area A of each of the
tubes 110 multiplied by a quantity n of the tubes 110 attached to
the tank inlet part 140a equals the total area A1 of the passage
sectional areas (i.e., A.times.n=A1). The tank body 150 of the
present embodiment has a shape satisfying expressions of D1>D2
and D2.times.L.gtoreq.A1 (i.e., D2.times.L.gtoreq.A.times.n).
[0076] As described above, the tank body 150 is configured to
satisfy the expression of D1>D2.
[0077] Accordingly, it can suppress that a sear drop is formed in a
corner of a junction area in which the space defining part 152 and
the tank junction part 153 connect to each other, i.e., in which
the tank body 150 is attached to the intermediate plate 170.
Therefore, it can suppress that stress is applied to the sear drop
intensively even when a pressure inside the header tank 140
increases.
[0078] In addition, the pressing is not required to be performed
repeatedly so as to provide the junction area, in which the space
defining part 152 connects to the tank junction part 153, to be a
square shape when providing the tank body 150 by pressing.
Accordingly, a deterioration of the productivity can be suppressed.
Therefore, the header tank 140 of the present embodiment can
certainly have high pressure resistance while productivity is
improved.
[0079] Moreover, a pressure inside the tank body 150 applies a
stress to the junction edge 158 in a direction in which the
junction edge 158 is pressed against intermediate plate 170 by
configuring the tank body 150 to satisfy the expression of
D1>D2. The direction in which junction edge 158 is pressed
against the intermediate plate 170 is, i.e., a radial outward
direction of the inscribed circle of the passage 151 shown by the
dashed line in FIG. 6. As a result, the tank body 150 and the
intermediate plate 170 can be prevented from being separated from
each other even when the brazing between the tank body 150 and the
intermediate plate 170 is insufficient. Therefore, the pressure
resistance can be secured certainly.
[0080] Here, an opening area of the opening 155 of the tank body
150 becomes small when the distance (D2) between the junction edges
158, adjacent to each other in the width direction when viewing the
tank body 150 in the tube stacking direction, is set too small. In
this case, a pressure loss of the fluid flowing in or flowing out
of the passage 151 may increase.
[0081] According to the present embodiment, the tank body 150 has a
shape satisfying an expression of D2.times.L.gtoreq.A1. As a
result, the opening area (D2.times.L) of the opening 155, which is
an inlet/outlet of the tank body 150 with respect to the passage
151, can be larger than or equal to the total area (A1) of the
passage sectional areas of the tubes 110. Therefore, an increase of
the pressure loss of the fluid flowing in or flowing out of the
passage 151 can be suppressed.
Second Embodiment
[0082] A second embodiment will be described hereafter referring to
FIG. 7. The second embodiment is different from the above-described
first embodiment in configurations of the tank body 150 and the
intermediate plate 170.
[0083] As shown in FIG. 7, the space defining part 152 of the tank
body 150 has substantially a U-shape in a cross section when viewed
in the tube stacking direction. The junction end surface 156 of the
tank body 150 has an arc shape protruding toward the passage
151.
[0084] The intermediate plate 170 has the part corresponding to the
junction end surface 156. The part is provided with a protruding
portion 173 that protrudes toward the tank body 150 (i.e., upward
in a paper showing FIG. 7). The protruding portion 173 has
substantially a triangular shape in a cross section when viewed in
the tube stacking direction. The protruding portion 173 has a
receiving surface 174 and a vertical surface 175. The receiving
surface 174 is attached to the junction end surface 156 of the tank
body 150. The receiving surface 175 is perpendicular to the width
direction.
[0085] The receiving surface 174 has an arc shape fitting the arc
shape of the junction end surface 156. That is, the receiving
surface 174 has the same arc shape as that of the junction end
surface 156.
[0086] The vertical surface 175 connects to an edge of the
receiving surface 174 on a side adjacent to the tank body 150. The
vertical surface 175 connects to the inner wall surface of the
space defining part 152 smoothly. That is, the vertical surface 175
and the inner wall surface of the space defining part 152 provide a
seamless single flat surface. In other words, the vertical surface
175 and the inner wall surface of the space defining part 152
connect to each other without providing any step.
[0087] As described above, the protruding portion 173 of the
intermediate plate 170 is provided with the receiving surface 174
having the arc shape fitting the arc shape of the junction end
surface 156 of the tank body 150. Accordingly, the inner wall
surface of the tank body 150 and an inner wall surface of the
intermediate plate 170 can connect to each other smoothly.
[0088] Accordingly, it can suppress that an insufficient junction
part is formed in the junction part in which the space defining
part 152 connects to the tank junction part 153, i.e., in a corner
of a junction part in which the tank body 150 is attached to the
intermediate part 170. Therefore, it can suppress that stress is
intensively applied to the corner of the junction part in which the
tank body 150 is attached to the intermediate part 170 when the
pressure inside the header tank 140 increases.
[0089] In addition, the pressing process is not necessary to
provide the junction area in which the space defining part 152
connects to the tank junction part 153 to have a square shape,
thereby a quantity of machining processes can be reduced.
Therefore, the header tank 140 of the present embodiment can
certainly have high pressure resistance while productivity is
improved.
Third Embodiment
[0090] A third embodiment will be described hereafter referring to
FIG. 8. The third embodiment is different from the second
embodiment in a configuration of the intermediate plate 170.
[0091] As shown in FIG. 8, the intermediate plate 170 of the
present embodiment has an intermediate junction part 176 and a
protruding part 177. The intermediate junction part 176 is attached
to the tank junction part 153 of the tank body 150. The protruding
part 177 is located closer to the top 154 of the tank body 150 as
compared to the intermediate junction part 176. The intermediate
junction part 176 and the protruding part 177 have a plate shape
extending in a direction perpendicular to the tube stacking
direction. The intermediate junction part 176 is provided
integrally with the protruding part 177.
[0092] The protruding part 177 has the plate hole 171. That is, the
protruding part 177 is provided with a communicating portion
through which the tube end 111 connects to the passage 151.
[0093] The protruding part 177 has two edges facing each other in
the width direction, and two of the intermediate junction parts 176
connect to the two edges of the protruding part 177 respectively.
The intermediate junction part 176 and the protruding part 177
connect to each other in a junction. A surface of the junction
adjacent to the tank body 150 is attached to the junction end
surface 156. Accordingly, the surface of the junction in which the
intermediate junction part 176 and the protruding part 177 connect
to each other configures the receiving surface 174 that is attached
to the junction end surface 156 of the tank body 150.
[0094] As described above, according to the present embodiment, the
intermediate junction part 176 and the protruding part 177 connect
to each other in the junction. The junction has the receiving
surface 174 having the arc shape fitting the arc shape of the
junction end surface 156 of the tank body 150. As a result, the
inner wall surface of the tank body 150 and the inner wall surface
of the intermediate plate 170 can connect to each other smoothly,
thereby the same effects as the second embodiment can be
obtained.
Fourth Embodiment
[0095] According to the present embodiment, a distance D2 between
the junction edges 158 of the tank body 150 in the width direction,
a thickness dimension t1 of the plate hole 171, and the passage
sectional area A of each of the tubes 110 are defined as shown in
FIG. 9. FIG. 9 illustrates a diagram corresponding to a cross
sectional view taken along a line IX-IX shown in FIG. 3 regarding
the first embodiment.
[0096] Specifically, the header tank 140 of the present embodiment
has a shape satisfying an expression of D2.times.t1.gtoreq.A. That
is, the header tank 140 of the present embodiment has the shape
satisfying expressions of D1>D2, D2.times.L.gtoreq.A.times.n,
and D2.times.t1.gtoreq.A. Other configurations of the refrigerant
radiator 100 are the same as the first embodiment.
[0097] Therefore, according to the header tank 140 and the
refrigerant radiator 100 of the present embodiment, the same
effects as the first embodiment can be obtained.
[0098] The communicating part 155, 171 has a part to which one tube
110 is connected. An opening area (expressed by D2.times.t1) of the
part can be set larger than the passage sectional area A of each of
the tubes 110. As a result, an increase of a pressure loss caused
when the refrigerant flows into the passage 151 from the tubes 110
can be suppressed more effectively. Alternatively, an increase of a
pressure loss caused when the refrigerant flows into the tubes 110
from the passage 151 can be suppressed more effectively.
Fifth Embodiment
[0099] The present embodiment is different from the third
embodiment in a configuration of the intermediate plate 170 in the
header tank 140.
[0100] Specifically, according to the present embodiment, the
protruding part 177 of the intermediate plate 170 protrudes toward
the passage 151 over the end of the receiving surface 174 adjacent
to the passage 151 as shown in FIG. 10. The protruding part 177 has
side surfaces facing each other in the width direction, and the
side surfaces has flat surfaces 174a respectively. The flat
surfaces 174a are attached to the inner wall surface of the space
defining part 152 by brazing. FIG. 10 illustrates a cross-sectional
view corresponding to the cross-sectional view in FIG. 8 regarding
the third embodiment.
[0101] The flat surfaces 174a expand parallel to the tube stacking
direction and the tube longitudinal direction. The inner surface of
the space defining part 152 has flat surfaces 156a to which the
flat surfaces 174a are attached respectively. Other configurations
of the refrigerant radiator 100 are the same as the first
embodiment.
[0102] Therefore, according to the header tank 140 and the
refrigerant radiator 100 of the present embodiment, the same
effects as the third embodiment can be obtained.
[0103] Moreover, the flat surfaces 174a of the protruding part 177
are attached to the inner wall surface of the space defining part
152, in addition to the attachment between the tank junction part
153 of the tank body 150 and the intermediate junction part 176 of
the intermediate plate 170. The junctions can cover the junction
end surface 156 in which the sear drop is easily formed by the
pressing. As a result, stress can be prevented, more effectively,
from being applied intensively to the corner of the junction area
in which the tank body 150 is attached to the intermediate plate
170 when the pressure inside the header tank 140 increases.
Modifications
[0104] It should be understood that the present disclosure is not
limited to the above-described embodiments and intended to cover
various modification within a scope of the present disclosure, for
example, as described hereafter. It should be understood that
structures described in the above-described embodiments are
preferred structures, and the present disclosure is not limited to
have the preferred structures. The scope of the present disclosure
includes all modifications that are equivalent to descriptions of
the present disclosure or that are made within the scope of the
present disclosure.
[0105] (1) According to the above-described embodiments, three
components (the tank body 150, the plate 160, and the intermediate
plate 170) configuring the header tank 140 are assembled (fixed
temporary) by a method such as fitting or fixing using a jig, and
then joined together by brazing. However, a method for joining the
three components 150, 160, and 170 are not limited to the
above-described example.
[0106] For example, as shown in FIG. 11, the ribs 162 of the plate
160 may have clicks 164 as a swaging part. In this case, the three
components 150, 160, 170 are deformed plastically and fixed
temporary by the clicks 164, and then joined together by
brazing.
[0107] (2) According to the above-described first embodiment, the
tank body 150 is formed by pressing. However, the tank body 150 may
be formed by extrusion molding.
[0108] (3) According to the above-described embodiment, single
passage 151 of the header tank 140 is provided, and any other
passage 151 is arranged adjacent to the single passage 151 in the
width direction. However, more than one of the passage 151 may be
arranged in the width direction similar to the tubes 110.
[0109] (4) According to the above-described embodiments, the tank
of the present disclosure is applied to the refrigerant radiator
100 disposed in the supercritical refrigeration cycle. However, the
tank of the present disclosure may be applied to an evaporator that
evaporates the refrigerant. Alternatively, the tank of the present
disclosure may be applied to a heat exchanger for a vehicle engine
etc. Furthermore, the refrigerant cycle is not limited to the
supercritical refrigeration cycle using carbon dioxide as the
refrigerant, and may be a normal refrigeration cycle. The tank of
the present disclosure may be applied to a device other than the
heat exchanger.
[0110] (5) According to the above-described embodiments, both the
inlet joint 191 and the outlet join 192 are attached to the one
header tank 140. However, the inlet joint 191 may be attached to
the one header tank 140, and the outlet joint 192 may be attached
to the other header tank 140. That is, the inlet joint 191 and the
outlet join 192 may be attached to different header tanks 140
respectively.
* * * * *